lock RENAULT TWINGO 2009 2.G Transmission Workshop Manual

20A-4
CLUTCH
Pressure plate - Disc: Removal - Refitting
D4F – D7F – K9K
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aLock the engine using tool (Mot. 582-01) (1) .
aRemove:
-the pressure plate bolts (2) ,
-the pressure plate and friction plate.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aDegrease the flywheel friction face.
aClean the clutch shaft splines. Special tooling required
Mot. 582-01Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts (D4F and D7F
engines)20 Nm
clutch pressure plate
bolts (K9K engine)15 Nm
108799

20A-6
CLUTCH
Pressure plate - Disc: Removal - Refitting
K4M
20A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery)
-the air filter box (see Air filter unit: Removal - Re-
fitting) (12A, Fuel mixture),
-the petrol injection computer (see Petrol injection
computer: Removal - Refitting) (17B, Petrol in-
jection),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see 21A, Manual gearbox, Manual
gearbox oils: Draining - Filling, page 21A-2) ,
-the engine cooling system (see Cooling system:
Draining - Refilling) (19A, Cooling),
-the refrigerant circuit (see Refrigerant circuit:
Draining - Filling) (62A, Air conditioning).aRemove:
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand driveshaft (see 29A, Drive-
shafts, Front left-hand driveshaft: Removal -
Refitting, page 29A-2) ,
-the front right-hand driveshaft (see 29A, Drive-
shafts, Front right-hand driveshaft: Removal -
Refitting, page 29A-8) .
-the engine - gearbox assembly (see Engine -
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals),
-the manual gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aPosition the (Mot. 1677) (1) .
aRemove:
-the clutch pressure plate bolts (2) ,
-the clutch pressure plate,
-the clutch plate. Special tooling required
Mot. 1677Flywheel locking tool.
Emb. 1780Set of clutch plate centr ing
mandrels.
Tightening torquesm
clutch pressure plate
bolts23 N.m
132329

21A-4
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
101388
(1) Oil defl ector
(2) Output shaft bear ing
(3) Output shaft
(4) First idle gear
(5) Synchroniser r ing
(6) First-second synchroniser hub
(7) Synchroniser r ing
(8) Lock r ing
(9) Splined w asher
(10) Second idle gear
(11) Splined w asher
(12) Lock r ing
(13) Splined w asher
(14) Third idle gear
(15) Synchroniser r ing
(16) Splined w asher
(17) Lock r ing
(18) Third-four th synchroniser hub
(19) Synchroniser r ing
(20) Four th idle gear (21) Lock washer
(22) Bear ing retaining clips on mech-
anism housing
(23) Output shaft bear ing
(24) Fifth fi xed gear
(25) Output shaft bolt
(26) Input shaft bear ing
(27) Primar y shaft
(28) Bear ing retaining clips on mech-
anism housing
(29) Input shaft bear ing
(30) Lock washer
(31) Ring under fifth idle gear
(32) Fifth idle gear
(33) Synchroniser r ing
(34) Synchroniser spring
(35) Fifth gear synchroniser hub
(36) Synchroniser spring
(37) Friction cone
(38) Retaining washer
(39) Input shaft nut

21A-5
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
(40) Synchroniser r ing
(41) Retaining washer
(42) Input shaft nut
141102
(79) Clutch control fork
(80) Fork pivot ball joint
(81) Pivot gaiter
(82) Assembled reverse gear shaft
(83) Bear ing ring
(84) Assembled 1-2 fork shaft claw
(85) Assembled 3-4 fork shaft claw
(86) Reverse gear guide
(87) Assembled 5th gear fork shaft
(88) Lip seal
(89) Gaiter
(90) Tie-bar
(91) Gaiter
(92) Shaft lever and finger assembly
(93) Thickness washer
(94) 5th gear kickdown point
(95) Gaiter (96) Ball joint bearing shell
(97) Lock ring
(98) Retur n spring

21A-7
MANUAL GEARBOX
Manual gearbox: List and location of components
JB1
21A
141101
(114) O-r ing
(115) Lip seal
(116) Lock r ing
(117) Ball bear ing
(118) Lock r ing
(119) Lip seal
(120) Differential line tightening nut
(121) Adjusting shim
(122) Roller bearing
(123) Tachometer control ring
(124) Tachometer control pinion
(125) Tachometer pinion shaft
(126) Locking pin
(127) Ball bear ing
(128) Washer
(129) Spring washer
(130) Assembled differential mecha-
nism
(131) Hollow sun wheel (132) Thrust w asher
(133) Stop washer

21A-8
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
JH1 or JH3
101388
(1) Oil defl ector
(2) Bear ing
(3) Output shaft
(4) First gear pinion
(5) Synchromesh r ing
(6) First-second gear synchroniser
hub
(7) Spring
(8) Roller
(9) Lock r ing
(10) Splined w asher
(11) Second gear pinion
(12) Third gear pinion
(13) Third-four th gear synchroniser
hub
(14) Four th gear pinion
(15) Lock washer
(16) Retaining clips (17) Bear ing
(18) Fifth gear pinion
(19) Output shaft bolt
(20) Bear ing guide
(21) Primar y shaft
(22) Retaining clips
(23) Bear ing
(24) Lock washer
(25) Sprocket supporting ring
(26) Fifth gear pinion
(27) Synchromesh r ing
(28) Spring
(29) Synchroniser hub
(30) Spring
(31) Friction cone
(32) Synchromesh r ing
(33) Washer
(34) Input shaft nut

21A-9
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
JR5
101389
(1) Oil defl ector
(2) Bear ing
(3) Output shaft
(4) First gear pinion
(5) Synchromesh r ing
(6) Spring
(7) First-second gear synchroniser
hub
(8) Synchromesh r ing
(9) Sprocket supporting ring
(10) Second gear pinion
(11) Splined w asher
(12) Sprocket supporting ring
(13) Third gear pinion
(14) Synchromesh r ing
(15) Third-four th gear synchroniser
hub
(16) Synchromesh r ing (17) Sprocket supporting ring
(18) Four th gear pinion
(19) Adjustment washer
(20) Bear ing
(21) Fifth gear pinion
(22) Output shaft bolt
(23) Bear ing guide
(24) Primar y shaft
(25) Retaining clips
(26) Bear ing
(27) Lock washer
(28) Sprocket supporting ring
(29) Fifth gear pinion
(30) Synchromesh r ing
(31) Spring
(32) Synchroniser hub
(33) Spring
(34) Friction cone

21A-10
MANUAL GEARBOX
Manual gearbox: List and location of components
JH1 or JH3 or JR5
21A
(35) Synchromesh r ing
(36) Washer
(37) Input shaft nut
101393
(38) Differential seal
(39) Bear ing
(40) Differential
(41) Tachometer sprocket (if fitted to
the vehicle)
(42) Satellite
(43) Sunwheel
(44) Axis
(45) Shaft retaining spr ing
(46) Fr iction cover
101390
(47) Selector shaft
(48) Gear shift catch
(49) Reverse gear brake fork and
shaft
(50) Fifth gear fork and shaft
(51) Pin
(52) Reverse gear shaft
(53) Third-four th gear fork and shaft
(54) Ring
(55) Lock shaft
(56) First-second gear fork and shaft
(57) Retaining locating ball car tridge
(58) Selector shaft bolt
(59) Reverse gear fork shaft bolt

21A-34
MANUAL GEARBOX
Manual gearbox: Repair
JB1
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION.
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aCheck the shafts (see Manual gearbox: Check) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the manual gearbox selector shaft (see Manual
gearbox selector shaft: Removal - Refitting) .
REFITTING
I - REFITTING PREPARATION OPERATION
aClean all the removed parts (see Manual gearbox:
Precautions for the repair) .
aReplace worn or damaged parts.
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the synchroniser hub springs,
-the removed bearings,
-the selector shaft rings,
-the spy seals,
-the hydraulic clutch thrust bearing (if equipped),
-the magnet.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) .
aRefit:
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) , IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .

21A-36
MANUAL GEARBOX
Manual gearbox: Repair
JH1 or JH3 or JR5
21A
REMOVAL
I - REPAIR PREPARATION OPERATION
aRemove the gearbox (see 21A, Manual gearbox,
Manual gearbox: Removal - Refitting, page 21A-
24) .
aPosition the gearbox on the component support (see
Gearbox support equipment: Use) .
II - REMOVAL OPERATION
aRemove:
-the fifth gear housing (see 5th gear housing: Re-
moval - Refitting) ,
-the fifth gear synchroniser and pinions (see 5th
gear sprockets and synchronisers: Removal -
Refitting) ,
-the mechanism housing (see Mechanism hous-
ing: Removal - Refitting) ,
-the gearbox shafts (see Gearbox shaft: Removal
- Refitting) ,
-the differential (see Manual gearbox differential:
Removal - Refitting) .
III - REPAIR OPERATION
aStrip down the output shaft (see Output shaft:
Stripping - Rebuilding) .
aRemove:
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) .aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) to clean all of the
removed parts.
aCheck (see Manual gearbox: Check) :
-the pinions (teeth, claws, friction cone, inner wall),
-the synchroniser hubs,
-the synchroniser rings,
-the bearings.
aReplace worn or damaged parts.
REFITTING
I - REFITTING PREPARATION OPERATION
aParts always to be replaced:
-the lip seals,
-the O-rings,
-the clutch thrust bearing guide,
-the gear lock rings,
-the roll pins,
-the input and output shaft bearing circlips,
-the selector rod hub springs,
-the hydraulic clutch slave cylinder (if fitted),
-the magnet,
-the selector shaft rings,
-the lock ring of the differential,
-the differential retaining nut.
II - REFITTING OPERATION
aRefit:
-the gearbox selector shaft (see Manual gearbox
selector shaft: Removal - Refitting) ,
-the bearings of the clutch housing (see Clutch
housing bearing: Removal - Refitting) ,
-the bearings of the mechanism housing (see
Mechanism housing bearing: Removal - Refit-
ting) ,
-the differential bearings (see Manual gearbox dif-
ferential bearing: Removal - Refitting) .
aRebuild the output shaft (see Output shaft: Strip-
ping - Rebuilding) . IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Manual gearbox: Precautions for the
repair) .